Cold atmospheric plasma‐mediated zearalenone degradation in corn: process optimization and nutritional quality implications

Abstract BACKGROUND Zearalenone (ZEN) is a heat‐stable Fusarium mycotoxin frequently detected in cereals and is of food‐safety concern because of its estrogenic and toxic effects. This study evaluated cold atmospheric plasma (CAP) for reducing ZEN in aqueous model systems and artificially contaminated corn and optimized the processing conditions using response surface methodology with a Box–Behnken design. RESULTS Treatment distance (2–6 cm), exposure time (20–300 s), and initial ZEN concentration (100–900 μg L −1 ) significantly affected ZEN reduction ( P < 0.05; adjusted R 2 = 0.9711). Under the optimized distance and time (2 cm and 300 s; model‐system center concentration 500 μg L −1 ), ZEN was not detected in the aqueous system (<1.8 μg L −1 , method detection limit). In artificially contaminated corn, ZEN decreased from 474 ± 55.50 to 278 ± 31.85 μg kg −1 , corresponding to a 41.27% reduction. CAP did not significantly alter crude protein, crude fat, titratable acidity, or amino acid composition. In contrast, α‐tocopherol decreased by approximately 94%, whereas β‐carotene increased, possibly because of enhanced extractability after plasma‐induced matrix modification. CONCLUSION CAP reduced the concentration of ZEN, but its efficacy was strongly matrix dependent and the treatment caused substantial α‐tocopherol loss. Because degradation products and their toxicological properties were not characterized, the present data demonstrate parent‐compound reduction rather than complete detoxification. Further process optimization and toxicological evaluation are required before application to cereal processing. © 2026 Society of Chemical Industry.